BLOCK AS 1649427 - Caterpillar

Illustration 10 g03442426
Fabricate plate (2) in order to support the new expansion tank group. Paint plate (2) once fabrication is completed. Refer to Illustration 9 and Illustration 10.Note: Fabricate plate (2) from a structural steel with a minimum yield of 290 MPa (42061 psi).
Illustration 11 g03442427
Assemble fabricated plate (2) on to the top plate assembly (E) with three bolts (3), three hard washers (4), and two hard washers (5). Tighten the bolts to a torque of 100 20 N m (74 15 lb ft). Refer to Illustration 11.
Illustration 12 g03442429
Assemble the new expansion tank group (6) on to fabricated plate (2) with two bolts (8) and two hard washers (7). Tighten the bolts to a torque of 15 3 N m (133 27 lb in). Refer to Illustration 12.
Illustration 13 g03442436
Arrow in the top show overflow line hoseArrow in the bottom show shunt line hose
Connect the current overflow line. Cut the hose if necessary and tie the hose with a cable strap (9) .
Connect the current shunt line. Cut the hose if necessary.
Maintain the shunt line hose with a hose clamp (11). Tighten the hose clamp to a torque of 7.5 1.0 N m (66.4 8.9 lb in). Refer to Illustration 13.
Install the new hose (10) (Vent line). The length of the hose should be 276 mm (10.9 inch).
Illustration 14 g03442437
Maintain the hose (10) (Vent line), with two band clamps (12). Tighten the band clamps to a torque of 7.5 1.0 N m (66.4 8.9 lb in). Refer to Illustration 14.
Illustration 15 g03442438
Illustration 16 g03444597
(AB) Dimension is 8.0 0.5 mm (0.31 0.02 inch) (AC) Dimension is 58.0 0.5 mm (2.28 0.02 inch) (AD) Dimension is 197.6 1.5 mm (7.78 0.06 inch) (AE) Dimension is 10.0 mm (0.39 inch) (AF) Dimension is 36.0 1.5 mm (1.41 0.06 inch) (AH) Dimension is 60.0 mm (2.36 inch)
Drill three holes on to the current hood in order to gain access to fill the expansion tank group. Paint the hood when complete in order to avoid rust. Refer to Illustration 15 and Illustration 16.
Illustration 17 g03442439
(AJ) Dimension is 156 mm (6.1 inch) (AK) Dimension is 20 mm (0.8 inch) (AL) Dimension is 78 mm (3.1 inch) (AM) Radius is 15 mm (0.6 inch) for all four corners (AN) Diameter is 10 mm (0.4 inch) (AS) Dimension is 5 mm (0.2 inch)
Illustration 18 g03444598
Fabricate plate (14) . Paint the plate once fabrication is completed. Refer to Illustration 17 and Illustration 18 for the dimensions.Note: Fabricate plate (14) from a structural steel with a minimum yield of 290 MPa (42061 psi).
Add seal (13) of length 624 mm (24.6 inch) on to the fabricated plate (14) perimeter in order to avoid damaging the hood paint.
Illustration 19 g03442440
Illustration 20 g03442441
Assemble the fabricated plate (14) on to top of the hood with two bolts (15), two washers (16), and two nuts (17). Refer to Illustration 19 and Illustration 20.
Fill the shunt tank and purge the system. The tank cap can be removed by